KTM 450 XC ATV 2009 Manual

SETUP INSTRUCTIONS 2009
450 XC ATV
525 XC ATV
Art. no. 3211617en

INTRODUCTION 1
INTRODUCTION
The work described in these setup instructions must be performed before the vehicle is delivered to the customer.
Read the setup instructions in their entirety before beginning work.
Print out the current PDI form found on the KTM DEALER.NET.
These setup instructions were written to correspond to the latest state of this series. We reserve the right to make changes in the inter-
est of technical advancement without at the same time updating this manual.
We shall not provide a description of general workshop methods. Likewise, safety rules that apply in a workshop are not specified here.
It is assumed that the work will be performed by a fully trained mechanic.
All specifications are non-binding. KTM Sportmotorcycle AG specifically reserves the right to modify or delete technical specifica-
tions, prices, colors, forms, materials, services, designs, equipment, etc., without prior notice and without specifying reasons, to adapt
these to local conditions, as well as to stop production of a particular model without prior notice. KTM accepts no liability for delivery
options, deviations from illustrations and descriptions, as well as misprints and other errors. The models portrayed partly contain spe-
cial equipment that does not belong to the regular scope of delivery.
© 2010 KTM-Sportmotorcycle AG, Mattighofen Austria
All rights reserved
Reproduction, even in part, as well as copying of all kinds, is permitted only with the express written permission of the copyright
owner.
ISO 9001(12 100 6061)
According to the international quality management standard ISO 9001, KTM uses quality assurance processes that lead
to the maximum possible quality of the products.
Issued by: TÜV Management Service
KTM-Sportmotorcycle AG
5230 Mattighofen, Austria

MEANS OF REPRESENTATION 2
Symbols used
The meaning of specific symbols is described below.
Indicates an expected reaction (e.g. of a work step or a function).
Indicates an unexpected reaction (e.g. of a work step or a function).
Identifies a page reference (more information is provided on the specified page).
Formats used
The typographical and other formats used are explained below.
Specific name Identifies a proprietary name.
Name®Identifies a protected name.
Brand™ Identifies a trademark.

SET‑UP 3
2.1Unpacking and setting up the vehicle
200151-10
–Remove the box and the plastic packaging.
–Check the vehicle for transport damage.
–Remove the vehicle from the palette.
–Unpack the separate enclosure and check its contents on the basis of the enclosure
list.
–Remove the rear fender. ( p. 5)
Warning
Risk of injury Battery acid and battery gases cause serious cauterization.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open fire. Charge only in well ven-
tilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery
acid gets in the eyes, rinse with water for at least 15 minutes and con-
tact a doctor.
–Fill the battery.
Info
Observe the instructions in the separate enclosure of the battery.
–Recharge the battery. ( p. 6)
–Install the battery. ( p. 7)
–Fill up with fuel. ( p. 7)
100107-10
–Insert the ignition key in the key cover cap .
Info
The key cover cap is in the tool set.
Read the installation instructions on the inside of the cap.
–Print out the current PDI form found on KTM DEALER.NET and perform the delivery
inspection.

WORK 4
3.1Adjusting the handlebar position
100100-10
–Pull the instrument support off the handlebar and swing it to the side.
Info
Protect the vehicle and its attachments from damage by covering them.
Do not bend the cables and lines.
100099-10
–Remove the four screws . Remove handlebar clamps , swing the handlebar for-
ward and set it down.
–Remove nuts and remove handlebar support with the screws.
–Remove screws and .
–Remove screws . Remove handlebar bridge .
–Place handlebar bridge onto the steering column in the desired position. Mount
and tighten screw .
Guideline
Screw, steering bridge M8 20 Nm
(14.8 lbf ft)
–Mount and tighten screw .
Guideline
Screw, steering column, top M20x1.5 25 Nm
(18.4 lbf ft)
–Mount and tighten screws .
Guideline
Screw, steering bridge M8 20 Nm
(14.8 lbf ft)
–Mount handlebar support in the desired position using the screws. Mount new
self-locking nuts and tighten.
Guideline
Nut, handlebar support M10 45 Nm
(33.2 lbf ft)
–Position the handlebar and fix it with handlebar clamps . Mount and tighten
screws .
Guideline
Screw, handlebar clamp M8 20 Nm
(14.8 lbf ft)
Info
Make sure cables and wiring are positioned correctly.
–Position the instrument support on the handlebar.
3.2Removing the seat
100041-10
–Pull the release hook back. Lift up the seat at the rear, pull it back and then
remove from above.

WORK 5
3.3Mounting the seat
100046-10
–Hook slot on the seat into collar sleeve of the fuel tank, lower the rear of the
seat and slide tab under fuel tank .
100043-10
–Push down the rear of the seat until release hook engages.
–Make sure that the seat is correctly locked in.
3.4Removing the rear fender
–Remove the seat ( p. 4)
200149-10
–Remove screws .
200148-10
–Raise the rear of the air filter box lid . At the same time, use your other hand to
press on the carburetor connection boot to kink it at that location. This prevents the
carburetor connection boot from disconnecting from the carburetor.
–Raise fender at the rear and remove it.

WORK 6
3.5Installing the rear fender
200148-11
–Raise the rear of air filter box lid . At the same time, use your other hand to press
on the carburetor connection boot to kink it at that location. This prevents the car-
buretor connection boot from disconnecting from the carburetor.
–Position front fender .
–Fix the air filter box lid in the fender.
Info
If the air filter box lid is not correctly mounted, dust and dirt can penetrate
into the engine and cause damage.
200149-11
–Mount and tighten screws .
Guideline
Remaining screws, chassis M6 10 Nm (7.4 lbf ft)
–Mount the seat. ( p. 5)
3.6Recharging the battery
Warning
Risk of injury Battery acid and battery gases cause serious cauterization.
–Keep batteries out of the reach of children.
–Wear suitable protective clothing and goggles.
–Avoid contact with battery acid and battery gases.
–Keep the battery away from sparks or open fire. Charge only in well ventilated rooms.
–In the event of skin contact, rinse with large amounts of water. If battery acid gets in the eyes, rinse with water for at least
15 minutes and contact a doctor.
Warning
Environmental hazard Battery parts and acid are harmful to the environment.
–Do not discard batteries with the household trash. Dispose of a defective battery in an environmentally compatible manner.
Give the battery to your KTM dealer or to a recycling center that accepts used batteries.
Warning
Environmental hazard Hazardous substances cause environmental damage.
–Oil, grease, filters, fuel, cleaners, brake fluid, etc., should be disposed of as stipulated in applicable regulations.

WORK 7
Info
Even if there is no load on the battery, it still loses power steadily.
The charge state and the type of charge are very important for the service life of the battery.
Rapid charging with a high charging current has a negative impact on the service life.
If the charging current, charging voltage and charging time are exceeded, electrolyte escapes via the safety valves. This
reduces the battery capacity.
If the vehicle is started repeatedly until the battery is depleted, the battery must be charged immediately.
If the battery is left in a discharged state for an extended period, it will drain completely and sulfate, destroying the battery.
The battery is maintenance-free, which means that the acid level does not need to be checked.
–Switch off all power consumers and switch off the engine.
–Remove the rear fender. ( p. 5)
–Disconnect the minus (negative) cable of the battery to avoid damage to the vehi-
cle's electronics.
100087-10
–Connect the battery charger to the battery. Switch on the battery charger.
Battery charger (58429074000)
You can also use the battery charger to test rest potential and start potential of the
battery, and to test the alternator. With this device, you cannot overcharge the bat-
tery.
Info
Never remove the lid .
Charge the battery to a maximum of 10% of the capacity specified on the
battery housing .
–Switch off the charger after charging. Disconnect the battery.
Guideline
The charge current, charge voltage and charge time must not be exceeded.
Charge the battery regularly when the
vehicle is not in use
3 months
–Install the rear fender. ( p. 6)
3.7Installing the battery
200150-11
–Place the battery in the battery holder.
Battery (YTX5L-BS)
–Reconnect rubber band .
–Attach the positive (plus) cable and replace the plus pole cover .
–Connect the negative (minus) cable of the battery.
–Install the rear fender. ( p. 6)
3.8Refueling
Danger
Fire hazard Fuel is highly flammable.
–Never refuel the vehicle near open flames or burning cigarettes, and always switch off the engine first. Be careful that no
fuel is spilt, especially on hot vehicle components. Clean up spilt fuel immediately.
–Fuel in the fuel tank expands when warm and can escape if the tank is overfilled. See the notes on refueling.
Warning
Danger of poisoning Fuel is poisonous and a health hazard.
–Avoid contact of the fuel with skin, eyes and clothing. Do not inhale fuel vapors. If fuel gets into your eyes, rinse imme-
diately with water and contact a doctor. Wash affected skin areas immediately with soap and water. If fuel is swallowed,
contact a doctor immediately. Change clothing that has come into contact with fuel.

WORK 8
Warning
Environmental hazard Improper handling of fuel is a danger to the environment.
–Do not allow fuel to get into the ground water, the ground, or the sewage system.
400287-10
–Switch off the engine.
–Open the filler cap.
–Fill the fuel tank with fuel up to measurement .
Guideline
Measurement of 35 mm (1.38 in)
Total fuel tank
capacity approx.
13.5 l
(3.57 US gal)
Super unleaded (ROZ 95 / RON 95 /
PON 91) ( p. 10)
–Close the filler cap.

TECHNICAL DATA - CHASSIS TIGHTENING TORQUES 9
Remaining nuts, chassis M6 15 Nm (11.1 lbf ft) –
Remaining screws, chassis M6 10 Nm (7.4 lbf ft) –
Screw on fuel tank M6 6 Nm (4.4 lbf ft) –
Screw, clamping nut, rear axle M6 10 Nm (7.4 lbf ft) –
Screw, foot brake cylinder M6 7 Nm (5.2 lbf ft) Loctite®243™
Screw, rear brake caliper M6 10 Nm (7.4 lbf ft) Loctite®243™
Remaining nuts, chassis M8 30 Nm (22.1 lbf ft) –
Remaining screws, chassis M8 25 Nm (18.4 lbf ft) –
Screw, bearing support, steering M8 25 Nm (18.4 lbf ft) –
Screw, front brake caliper M8 20 Nm (14.8 lbf ft) Loctite®243™
Screw, front brake disc M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, handlebar clamp M8 20 Nm (14.8 lbf ft) –
Screw, rear brake caliper M8 20 Nm (14.8 lbf ft) Loctite®243™
Screw, rear brake disc M8 25 Nm (18.4 lbf ft) Loctite®243™
Screw, rear wheel eccentric element M8 20 Nm (14.8 lbf ft) –
Screw, steering bridge M8 20 Nm (14.8 lbf ft) –
Screw, subframe M8 35 Nm (25.8 lbf ft) Loctite®243™
Engine bracket screw M10 60 Nm (44.3 lbf ft) –
Engine mounting bolt M10 60 Nm (44.3 lbf ft) –
Nut, handlebar support M10 45 Nm (33.2 lbf ft) –
Remaining nuts, chassis M10 50 Nm (36.9 lbf ft) –
Remaining screws, chassis M10 45 Nm (33.2 lbf ft) –
Screw, A-arm bottom M10x70 45 Nm (33.2 lbf ft) –
Screw, A-arm top M10x52 45 Nm (33.2 lbf ft) –
Screw, footrest M10 45 Nm (33.2 lbf ft) –
Screw, front shock absorber M10 45 Nm (33.2 lbf ft) –
Screw, steering column at bottom of
steering lever
M10 25 Nm (18.4 lbf ft) –
Nut, ball head, A-arm top M10x1.25 35 Nm (25.8 lbf ft) –
Nut, rear sprocket screw M10x1.25 45 Nm (33.2 lbf ft) Loctite®243™
Nut, tie rod end M10x1.25 45 Nm (33.2 lbf ft) –
Wheel nut M10x1.25 45 Nm (33.2 lbf ft) –
Nut, front wheel hub M12 70 Nm (51.6 lbf ft) –
Screw, rear bottom shock absorber M12 70 Nm (51.6 lbf ft) –
Screw, rear top shock absorber M12 60 Nm (44.3 lbf ft) –
Lock nut, tie rod, inside M12LHx1.25 20 Nm (14.8 lbf ft) –
Lock nut, tie rod, outside M12x1.25 20 Nm (14.8 lbf ft) –
Nut, A-arm top M12x1.25 30 Nm (22.1 lbf ft) –
Nut, ball head, A-arm bottom M12x1.5 40 Nm (29.5 lbf ft) –
Nut, swingarm pivot M16x1.5 100 Nm (73.8 lbf ft) –
Nut, rear wheel hub M18x1.5 130 Nm (95.9 lbf ft) –
Screw, steering column, bottom M20x1.5 40 Nm (29.5 lbf ft) –
Screw, steering column, top M20x1.5 25 Nm (18.4 lbf ft) –
Clamping nut, rear axle 2"-10UNS-2B-LH 25 Nm (18.4 lbf ft) Only applies when using:
Open-end wrench
attachment, 46 mm
(83019010461)

SUBSTANCES 10
Super unleaded (ROZ 95 / RON 95 / PON 91)
According to
–DIN EN 228 (ROZ 95 / RON 95 / PON 91)

*3211617en*
3211617en
KTM-Sportmotorcycle AG
5230 Mattighofen/Austria
http://www.ktm.com
02/2010
Photo: Mitterbauer